U.S. patent application number 15/215019 was filed with the patent office on 2017-02-02 for batch charge conveying systems for electric induction furnaces.
The applicant listed for this patent is INDUCTOTHERM CORP.. Invention is credited to TED HAINES, SATYEN N. PRABHU, NIKITA SKORODINSKI.
Application Number | 20170030648 15/215019 |
Document ID | / |
Family ID | 57882456 |
Filed Date | 2017-02-02 |
United States Patent
Application |
20170030648 |
Kind Code |
A1 |
HAINES; TED ; et
al. |
February 2, 2017 |
BATCH CHARGE CONVEYING SYSTEMS FOR ELECTRIC INDUCTION FURNACES
Abstract
A batch charge conveying system is provided for multiple
electric induction furnaces where each one of the multiple furnaces
has a separate charge conveying apparatus. An assembled batch
charge is loaded on a single assembled batch charge transport
apparatus that selectively delivers the assembled batch charge to a
separate charge conveying apparatus associated with one of the
multiple electric induction furnaces.
Inventors: |
HAINES; TED; (WESTAMPTON,
NJ) ; PRABHU; SATYEN N.; (VOORHEES, NJ) ;
SKORODINSKI; NIKITA; (PHILADELPHIA, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
INDUCTOTHERM CORP. |
RANCOCAS |
NJ |
US |
|
|
Family ID: |
57882456 |
Appl. No.: |
15/215019 |
Filed: |
July 20, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62198180 |
Jul 29, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F27D 2003/006 20130101;
F27D 3/0031 20130101; F27D 11/06 20130101; F27D 3/0025 20130101;
F27D 2003/0062 20130101; F27D 2003/0038 20130101; F27D 3/06
20130101 |
International
Class: |
F27D 3/06 20060101
F27D003/06; F27D 11/06 20060101 F27D011/06; F27D 3/00 20060101
F27D003/00 |
Claims
1. A batch charge conveying system for two or more electric
induction furnaces, the batch charge conveying system comprising: a
separate charge conveying apparatus for conveying an assembled
batch charge to each one of the two or more electric induction
furnaces, the separate charge conveying apparatus having a
conveying charge load end and a furnace charge load end; and a
single assembled batch charge transport apparatus for receiving a
selected charge materials forming the assembled batch charge on the
single assembled batch charge transport apparatus, the single
assembled batch charge transport apparatus having an assembled
batch charge transport driver system arranged to move the single
assembled batch charge transport apparatus with the assembled batch
charge to a conveyor charge loading station adjacent to the
conveying charge load end of one of the separate charge conveying
apparatus for transfer of the assembled batch charge to the one of
the separate charge conveying apparatus.
2. The batch charge conveying system for two or more electric
induction furnaces of claim 1 further comprising a single batch
charge loading station for the single assembled batch charge
transport apparatus to receive the selected charge materials, the
assembled batch charge transport driver system arranged to move the
single assembled batch charge transport apparatus between the
single batch charge loading station and the conveyor charge loading
station for each of the separate charge conveying apparatus.
3. The batch charge conveying system for two or more electric
induction furnaces of claim 1 further comprising a batch charge
loading station for the single assembled batch charge transport
apparatus collocated with the conveyor charge loading station for
at least one of the separate conveying apparatus.
4. The batch charge conveying system for two or more electric
induction furnaces of claim 1 further comprising a means for moving
of the separate conveying apparatus between a conveyor charge
loading position for the transfer of the assembled batch charge
from the single assembled batch charge transport apparatus to the
separate conveying apparatus and a conveyor furnace charge loading
position for the transfer of the assembled batch charge from the
separate conveying apparatus.
5. A method of conveying an assembled batch furnace charge to one
of a separate charge conveying apparatus for each one of a
plurality of electric induction furnaces, the method comprising
sequentially performing the following steps: (a) loading an
assembled batch charge onto a single assembled batch charge
transport apparatus at a batch charge loading station; (b) moving
the single assembled batch charge transport apparatus with the
assembled batch charge to a selected one of a separate batch charge
loading station associated with each of the separate charge
conveying apparatus; (c) transferring the assembled batch charge on
the single assembled batch charge transport apparatus input
position to the separate charge conveying apparatus at the selected
one of the separate batch charge loading station to form an
unloaded single assembled batch charge transport apparatus; and (d)
moving the unloaded single assembled batch charge transport
apparatus to the batch charge loading station and sequentially
repeating steps (a) through (c) at the remaining separate batch
charge loading stations associated with each of the remaining
separate charge conveying apparatus to optimize process time when
repeatedly melting, melt heating, and melt drawing in each of the
plurality of electric induction furnaces with charging each of the
plurality of electric induction furnaces with a single assembled
batch charge transport apparatus.
6. The method of claim 5 wherein the step of loading the selected
assembled batch charge is performed at one of the separate batch
charge loading stations.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/198,180, filed Jul. 29, 2015, which is hereby
incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to batch charge
conveying systems for electric induction furnaces and in particular
to such batch charge conveying systems where a furnace batch charge
can be selectively supplied to two or more electric induction
furnaces.
BACKGROUND OF THE INVENTION
[0003] Batch melting in an electric induction furnace is a process
in which the furnace is emptied of molten metal (melt) after a
supplied batch of solid metal charge has been melted and heated to
a required temperature. Successive melts are started by delivering
unheated or preheated solid charge materials to the furnace and
repeating the melting and melt heating process before drawing the
melt from the furnace. Preferable batch charge conveying systems
quickly deliver batch charge material (load) to an induction
furnace to allow maximum utilization of the induction furnace
heating and melting process. One class of charge conveying systems
utilizes conveyors, such as belt or vibratory conveyors (referred
to herein as charge conveying apparatus) to deliver batch charge
materials to the crucible of the induction furnace. With a belt
conveyor the assembled batch charge travels along the conveyor to
the furnace on a moving belt. With a vibratory conveyor the
assembled batch charge travels along a vibrating surface designed
to advance the assembled batch charge to the furnace. Examples of
vibratory conveyors are provided in U.S. Pat. Nos. 5,213,200 and
6,041,915.
[0004] One example of an in-line batch charge conveyor system 10 is
illustrated in FIG. 1(a) and FIG. 1(b) where a stationary batch
charge assembly station 12 feeds an assembled solid batch charge to
charge conveying apparatus 14 that deposits the assembled solid
batch charge to the crucible of single induction furnace 16 for
electric induction melting and melt heating to a required
temperature with subsequent drawing of the melt from the furnace,
for example, by pouring into an assembly line of molds or a launder
system. The assembled batch charge consists of selected solid
charge materials that are controlled by weight and/or chemical
composition to ensure that the assembled batch charge conveyed to
induction furnace 16 will produce a desired quantity and/or
chemical composition of molten material (metal, alloy or other
material) in the furnace. The selected charge materials are
delivered to the batch charge assembly station by suitable material
handling and transfer apparatus, for example, a charge material
conveyor upon which measured portions of different charge materials
are deposited at different charge material storage stations and
delivered to the batch charge assembly station. The charge
conveying apparatus can be, for example, a bidirectional
(.+-.X-direction in FIG. 1(a)) moveable conveying apparatus where
the conveying apparatus has a furnace charge load position as
illustrated in FIG. 1(a) for depositing the assembled batch charge
on the conveyor apparatus to the crucible of induction furnace 16
and a conveyor charge load position as illustrated in FIG. 1(b)
with the left end of the conveying apparatus retracted from
induction furnace 16, for example, to make space available for
other furnace servicing equipment, and the right end of the
conveying apparatus is positioned adjacent to stationary batch
charge assembly station 12 for transfer of the assembled batch
charge from the stationary batch charge assembly station to
conveying apparatus 14. Conveying apparatus 14 then moves the
assembled batch charge from the right end of the conveying
apparatus to the left end of the conveying apparatus, for example,
by a belt or vibratory conveyor along the length (X-direction) of
the conveying apparatus to the crucible of induction furnace 16
when conveying apparatus 14 is in the furnace charge load position
shown in FIG. 1(a). Movement of conveying apparatus 14 between the
furnace charge load position in FIG. 1(a) and the conveyor charge
load position in FIG. 1(b) can be accomplished by any suitable
means.
[0005] As shown in the alternative arrangement of FIG. 2 charge
conveying apparatus 14' may be provided with switchable multiple
conveyor lanes 14a' and 14b', for example, by a vibratory conveyor
with moveable conveyor gate 15 to direct the assembled batch charge
to furnace 16b when the gate is in the position shown in a solid
line, and to furnace 16a when gate 15 is rotated in the direction
indicated by the arrow to the position shown in a dashed line. As
with the example in FIG. 1(a) and FIG. 1(b) charge conveying
apparatus 14' can travel between the furnace charge load position
shown in FIG. 2 where an assembled batch charge loaded onto the
conveying apparatus can be delivered to the selected furnace and
the conveyor charge load position (not shown in the drawings) where
an assembled batch charge can be transferred from the stationary
batch charge assembly station 12 to conveying apparatus 14'.
[0006] In other arrangements where there are multiple induction
furnaces, for example, a quantity of two furnaces 16a and 16b in a
foundry as shown in FIG. 3, separate dedicated stationary batch
charge assembly stations 12a and 12b are provided for each of the
two induction furnaces 16a and 16b. This arrangement is inefficient
since, for example, furnace batch charging in multiple furnace
installations can be alternated, for example, with melting and melt
heating of the supplied batch charge in the first induction furnace
being performed while the second induction furnace has finished
drawing molten material and is ready to receive another assembled
batch charge for melting and melt heating. In the arrangement of
FIG. 3 one of the two stationary batch charge assembly station can
be idle (for the induction furnace currently in the batch charge
melting and melt heating or drawing process) and not being
used.
[0007] It is an object of the present invention to eliminate the
inefficiency, and the cost, of multiple batch charge assembly
stations when multiple batch melting induction furnaces require
batch charge loading, for example, in a foundry installation.
BRIEF SUMMARY OF THE INVENTION
[0008] In one aspect the present invention is apparatus for, and
method of, delivering an assembled batch charge from a single
assembled batch charge transport apparatus selectively between two
or more electric induction furnaces.
[0009] In another aspect the present invention is apparatus for,
and method of, delivering an assembled batch charge from a single
assembled batch charge transport apparatus selectively between two
or more electric induction furnaces where each furnace is supplied
with an assembled batch charge via a separate conveying apparatus
dedicated to each one of the two or more electric induction
furnaces.
[0010] The above and other aspects of the invention are set forth
in this specification and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The appended drawings, as briefly summarized below, are
provided for exemplary understanding of the invention, and do not
limit the invention as further set forth in this specification and
the appended claims.
[0012] FIG. 1(a) and FIG. 1(b) diagrammatically illustrate one
example of an in-line batch charge conveying system where a single
stationary batch charge assembly station serves a single electric
induction furnace via a charge conveying apparatus.
[0013] FIG. 2 diagrammatically illustrates one example of a single
stationary batch charge assembly apparatus selectively servicing
one of two electric induction furnaces via a switchable conveying
system supplying an assembled batch charge selectively to one of
the two furnaces by switching of the conveying path leading to one
of the two furnaces.
[0014] FIG. 3 diagrammatically illustrates another example of a
batch charge conveying system supplying an assembled batch charge
to each one of two induction furnaces where each of the two
induction furnaces has a dedicated batch charge assembly
station.
[0015] FIG. 4(a) through FIG. 4(e) diagrammatically illustrate one
example of a batch charge conveying system of the present invention
where a single assembled batch charge transfer apparatus
selectively supplies an assembled batch charge to any one of two
induction furnaces.
[0016] FIG. 5(a) and FIG. 5(b) diagrammatically illustrate another
example of a batch charge conveying system of the present invention
where a single assembled batch charge transfer apparatus
selectively supplies an assembled batch charge to any one of two
induction furnaces.
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 4(a) through FIG. 4(e) illustrate one example of a
batch charge conveying system 40 of the present invention for two
or more electric induction furnaces. Although the embodiment of the
invention in the figures is for two electric induction furnaces,
other embodiments of the invention comprise batch charge conveying
systems for more than two furnaces where the object is to optimize
process time with repeated process cycles of: delivering an
assembled batch charge to each furnace; melting the charge and melt
heating in each furnace;
[0018] and drawing the melt from each furnace where the batch
charge conveying system utilizes a single assembled batch charge
transport apparatus for delivering the assembled batch charge to
each furnace.
[0019] In FIG. 4(a) a single assembled batch charge transport
apparatus 20 is positioned between two charge conveying apparatus
14a and 14b. Charge conveying apparatus 14a is adjacent to batch
charge loading station "a" with conveying apparatus 14a provided to
supply an assembled batch charge to electric induction furnace 16a
and with charge conveying apparatus 14b provided to supply an
assembled batch charge to electric induction furnace 16b. In this
embodiment of the invention a single batch charge loading station
"a" for assembled batch charge transport apparatus 20 is located
separate from conveying apparatus batch charge loading stations "b"
and "c" for conveying apparatus 14a and 14b respectively. Selected
charge materials are delivered to batch charge loading station "a"
by a suitable material handling and transfer apparatus, for
example, a charge material conveyor upon which measured portions of
different charge materials are deposited at different charge
material storage stations and transferred to assembled batch charge
transport apparatus 20 at loading station "a" to form an assembled
batch charge on the assembled batch charge transport apparatus.
[0020] In FIG. 4(a) both conveying apparatus 14a and 14b are shown
in the retracted position (withdrawn from furnaces 16a and 16b
respectively) with their right ends (14a'' and 14b'') adjacent to
conveyor charge loading stations "b" and "c" respectively where the
assembled batch charge on assembled batch charge transport 20 can
be selectively transferred to the right end of either conveyor
apparatus 14a or 14b when the assembled batch charge transport is
moved from charge loading station "a" to either conveyor charge
loading station "b" or "c" respectively.
[0021] After the assembled batch charge load is transferred and
loaded on assembled batch charge transport station 20 in FIG. 4(a),
assembled batch charge transport apparatus 20 selectively moves to
conveyor charge loading station "b" in FIG. 4(b) and the assembled
batch charge on the assembled batch charge transport station 20 is
transferred to charge conveying apparatus 14a, which is in the
conveyor charge load position at loading station "b", while in FIG.
4(b) a previously assembled batch charge on the assembled batch
charge transport 20 has been transferred to conveyor apparatus 14b
and the conveyor apparatus 14b has moved to the furnace charge load
position to load antoher previously assembled batch charge into the
crucible of furnace 16b.
[0022] Transfer of the assembled batch charge on assembled batch
charge transport apparatus 20 to conveying apparatus 14a or 14b can
be accomplished by a transfer means such as a power driven belt or
a vibratory transfer table on the assembled batch charge transport
apparatus or a power driven hinged open-box bed on the transport
apparatus that dumps the assembled batch charge onto the selected
charge conveying apparatus.
[0023] After a previously assembled batch charge has been melted,
heated to a required melt temperature and drawn from furnace 16a,
conveying apparatus 14a with the assembled batch charge loaded in
FIG. 4(b) moves from the retracted conveyor position to the furnace
charge load position for loading of the assembled batch charge into
the crucible of furnace 16a as show in FIG. 4(c) while charge
conveyor apparatus 14b moves from the furnace charge load position
in
[0024] FIG. 4(b) to the retracted conveyor position adjacent to
conveyor charge load station "c" as shown in FIG. 4(c) and empty
(unloaded) assembled batch charge transport apparatus 20 moves to
batch charge loading station "a" as shown in FIG. 4(c).
[0025] After the assembled batch charge load is transferred and
loaded on assembled batch charge transport apparatus 20 in FIG.
4(c), assembled batch charge assembly station 20 selectively moves
to conveyor charge loading station "c" in FIG. 4(d) and the
assembled batch charge on the assembled batch charge transport
station 20 is transferred to charge conveying apparatus 14b, which
is in the conveyor charge load position at station "c" as shown in
FIG. 4(d).
[0026] In FIG. 4(e) after the previously assembled batch charge has
been melted, heated to a required melt temperature and drawn from
furnace 16b in FIG. 4(d), conveying apparatus 14b with the
assembled batch charge loaded in FIG. 4(d) moves from the retracted
conveyor position to the furnace charge load position to load the
assembled batch charge load into the crucible of furnace 16b as
show in FIG. 4(e) to begin a new batch melt while conveyor
apparatus 14a moves from the furnace charge load position to the
retracted conveyor position adjacent to load station "c" and empty
(unloaded) assembled batch charge transport apparatus 20 moves to
batch charge loading station "a".
[0027] In one embodiment of the invention the apparatus and process
described in FIG. 4(a) to FIG. 4(e) can be sequentially repeated
after the apparatus and process shown in FIG. 4(e) by returning to
the apparatus and process described sequentially from FIG. 4(b)
through FIG. 4(e). With the batch charge conveying system of the
present invention a single assembled batch charge transport
apparatus 20 is used to optimize process time and efficiency by
transferring an assembled batch charge to a charge conveyor
apparatus associated with a furnace that is completing the melting
and drawing process cycles while other furnaces in the system are
beginning or are in the melting and drawing process cycles.
[0028] Movement and repositioning of the single assembled batch
charge transport apparatus 20 in all embodiments of the invention,
for example, between loading stations "a", "b" and "c" in
[0029] FIG. 4(a) through FIG. 4(e), can be accomplished by an
assembled batch charge transport driver, for example, a wheelset
(wheel-axle assembly) attached to the single assembled batch charge
transport apparatus where the wheels move over rails installed at
ground level or in structure associated with supporting material
handling equipment.
[0030] Summarizing one embodiment of the invention, the batch
charge conveying system for two or more electric induction furnaces
has a separate charge conveying apparatus for conveying an
assembled batch charge to each one of the two or more electric
induction furnaces with the separate charge conveying apparatus
having an assembled batch charge receiving end and an assembled
batch charge furnace delivery end. A single assembled batch charge
transport apparatus receives selected charge materials forming the
assembled batch charge on the single assembled batch charge
transport apparatus. The single assembled batch charge transport
apparatus has an assembled batch charge transport driver arranged
to move the single assembled batch charge transport apparatus with
the assembled batch charge to a separate conveying apparatus batch
charge load station adjacent to the assembled batch charge
receiving end of a selected one of the separate charge conveying
apparatus for transfer of the assembled batch charge to the
selected one of the separate charge conveying apparatus.
[0031] In all embodiments of the invention selection of the order
in supplying the assembled batch charge to a furnace's charge
conveying apparatus can be made by a furnace control system based
upon where in the process cycle of loading charge; melting charge;
melt heating and drawing each furnace in a particular multiple
furnace system; a furnace in a multiple furnace that is finishing
the drawing of the melt from the furnace generally has the highest
priority for delivery of an assembled batch charge for the next
batch process of induction melting, heating and drawing of melt
from the furnace as known in the art.
[0032] FIG. 5(a) and FIG. 5(b) illustrate another embodiment of the
invention where the single batch load charge loading station "a" in
FIG. 4(a) through FIG. 4(e) is integrated into at least one of the
charge conveying apparatus batch loading stations "b" and "c" as
illustrated by reference sign (b+a) in FIG. 5(a) and FIG. 5(b) so
that as shown in FIG. 5(a) assembled batch charge transport
apparatus 20 can be loaded with an assembled batch charge at
loading station (b+a) and then selectively transfer the assembled
batch charge to charge conveying apparatus 14a for delivery to
electric induction furnace 16a at the same loading station (b+a) or
move to loading station "c" and transfer the assembled batch charge
to conveying apparatus 14b for delivery to electric induction
furnace 16b.
[0033] The process of the present invention can also be used in an
arrangement of three or more induction furnaces where the single
assembled batch charge transport apparatus moves among multiple
charge conveying apparatus dedicated to each of the three or more
induction furnaces to deliver an assembled batch charge to a
selected one of the multiple charge conveying apparatus while the
furnaces associated with the other multiple charge conveying
apparatus perform process steps associated with inductively
heating, melting and/or drawing molten material from the
furnaces.
[0034] In another embodiment of the invention a method of conveying
a selected assembled batch furnace charge from a single assembled
batch charge transport apparatus to a selected one of a separate
charge conveying apparatus for each one of a plurality of electric
induction furnaces is provided. In this embodiment the method the
sequentially performed steps include:
[0035] (a) positioning the single assembled batch charge transport
apparatus adjacent to a batch charge receiving end of the selected
one of the separate charge conveying apparatus;
[0036] (b) transferring the selected assembled batch furnace charge
on the single assembled batch charge transport apparatus to the
batch charge receiving end of the selected one of the separate
charge conveying apparatus;
[0037] (c) processing an inputted change in the selected assembled
batch furnace charge and an inputted change in the selected one of
the separate charge conveying apparatus in a furnace batch conveyor
control system;
[0038] (d) loading the selected assembled batch furnace charge
processed in step (c) on the single assembled batch charge
transport apparatus;
[0039] (e) positioning the single assembled batch charge transport
apparatus to an assembled batch charge delivery station adjacent to
the batch charge receiving end of the selected one of the separate
charge conveying apparatus processed in step (c);
[0040] (f) transferring the selected assembled batch furnace charge
processed in step (c) on the single assembled batch charge
transport apparatus to the batch charge receiving end of the
selected one of the separate charge conveying apparatus processed
in step (c); and
[0041] (g) sequentially repeating steps (c) through (f) to convey
the selected assembled batch furnace charge from a single assembled
batch charge transport apparatus to the selected one of the
separate charge conveying apparatus for each one of a plurality of
electric induction furnaces.
[0042] In the description above, for the purposes of explanation,
numerous specific requirements and several specific details have
been set forth in order to provide a thorough understanding of the
example and embodiments. It will be apparent however, to one
skilled in the art, that one or more other examples or embodiments
may be practiced without some of these specific details. The
particular embodiments described are not provided to limit the
invention but to illustrate it.
[0043] Reference throughout this specification to "one example or
embodiment," "an example or embodiment," "one or more examples or
embodiments," or "different example or embodiments," for example,
means that a particular feature may be included in the practice of
the invention. In the description various features are sometimes
grouped together in a single example, embodiment, figure, or
description thereof for the purpose of streamlining the disclosure
and aiding in the understanding of various inventive aspects.
[0044] The present invention has been described in terms of
preferred examples and embodiments. Equivalents, alternatives and
modifications, aside from those expressly stated, are possible and
within the scope of the invention.
* * * * *